Clothing components and articles of clothing including fabric woven with a multi-layered region and a single-layered region, and methods of making such woven fabrics

ABSTRACT

Components adapted for use in an article of clothing, and articles of clothing including such components, include a woven fabric comprising at least one multi-layered region and at least one single-layered region. The at least one multi-layered region can comprise a first woven fabric layer and a second woven fabric layer that is opposite from the first woven fabric layer, where the first and second woven fabric layers are separated from each other. The at least one multi-layered region and the at least one single-layered region can be weaved from the same sets of warps and wefts to form an integral fabric. Methods of making an item of apparel include forming a woven fabric comprising at least one multi-layered region and at least one single-layered region weaved from the same sets of warps and wefts, and cutting the woven fabric along a predetermined pattern to form one or more components.

TECHNICAL FIELD

The present disclosure relates generally to apparel. More specifically,various embodiments of the present disclosure relate to woven articlesof apparel and methods for making woven items of apparel.

BACKGROUND

Conventional items of apparel and garments (e.g., shirts, shoes, pants,jackets, etc.) are typically constructed by cutting a number ofdifferent components from one or more desired materials according topredetermined patterns. For example, a woven fabric may be obtained as adesired material, and components can be cut from the woven fabric alongpredetermined patterns. The various components cut from the one or moredesired materials are then typically coupled together in conventionalfashion, such as by sewing and/or adhering the various componentstogether.

Often, items of apparel include pockets and/or other openings, such asopenings for drawstrings, etc. that may require multiple components tobe sewed together, or may require the same component to be sewed toitself. For example, in conventional apparel items, pockets may beformed by sewing two or more components together. Other openings, suchas openings for a drawstring, may be formed by folding a portion of acomponent onto itself and sewing the portion of the component. Inaddition, items of apparel may also utilize multiple types of materialto incorporate various textures or visual effects to the apparel item.For example, an item of apparel may use two or more different types ofwoven fabric to incorporate various design effects into the apparel itemwhen completed.

In the manufacture of apparel and garments, sewing of pockets, openingsand varying types of material can increase the amount of time spentproducing each apparel item. By increasing the amount of time spent inproduction, the cost of production is also increased. Additionally, whentwo or more components are coupled together, the seams formed by suchcoupling (e.g., sewing, adhering, etc.) generally represent a weak pointin the item, where the apparel or garment is more likely to fail whenforces are applied that tend to pull the seams apart.

It would, therefore, be advantageous to provide apparel that can beformed with reduced sewing and fewer seams, while still enabling theapparel to include both functional features such as pockets and otheropenings, as well as visual features such as differing fabric patterns.

BRIEF SUMMARY

Various embodiments of the present disclosure relate to fabrics woven ina manner to provide various functional and/or ornamental features in asingle continuous web, as opposed to separate components being coupledtogether. According to at least one embodiment of the presentdisclosure, a component can be adapted for use in an article ofclothing, which component may include a woven fabric comprising at leastone multi-layered region and at least one single-layered region. The atleast one multi-layered region may comprise a first woven fabric layerand a second woven fabric layer that is opposite from the first wovenfabric layer, where the first and second woven fabric layers areseparated from each other. The woven fabric is configured to changebetween the at least one multi-layered region and the at least onesingle-layered region with the same sets of warps and wefts.

Other embodiments of the present disclosure include articles ofclothing. According to at least one embodiment, such articles ofclothing may comprise a plurality of components coupled together, whereat least one component of the plurality of components includes a wovenfabric. The woven fabric may include a multi-layered region comprising afirst woven fabric layer and a second woven fabric layer, where warpsand wefts of the first woven fabric layer are distinct from warps andwefts of the second woven fabric layer. The woven fabric may alsoinclude a single-layered region woven from the same groups of warps andwefts used in the first and second woven fabric layers of themulti-layered region.

Additional embodiments of the present disclosure include methods formaking an item of apparel. One or more implementations of such methodsmay include forming a woven fabric. The woven fabric may include atleast one multi-layered region comprising a first woven fabric layer anda second woven fabric layer that is opposite from the first woven fabriclayer, where the first and second woven fabric layers are separated fromeach other. The woven fabric may also include at least onesingle-layered region. The at least one multi-layered region and the atleast one single-layered region may be weaved from the same sets ofwarps and wefts. The woven fabric may be cut along a predeterminedpattern to form one or more components from the woven fabric. The one ormore components can also be coupled together to form at least a portionof the article of apparel.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Exemplary embodiments of the disclosure will become more fully apparentfrom the following description and appended claims, taken in conjunctionwith the accompanying drawings. Understanding that these drawings depictonly exemplary embodiments and are, therefore, not to be consideredlimiting of the disclosure's scope, the exemplary embodiments of thedisclosure will be described with additional specificity and detailthrough use of the accompanying drawings in which:

FIG. 1 is a cross section view of a woven fabric according to at leastone embodiment;

FIG. 2 is top view of a woven fabric illustrating an example of a 3×3weave pattern according to at least one embodiment;

FIG. 3 is a perspective view of a Jacquard Loom together with at leastone embodiment of weaving a woven fabric;

FIG. 4A is a cross-sectioned view of a portion of the Jacquard Loom ofFIG. 3 depicting four sets of alternating warp yarns interwoven with aset of weft yarns formed in a single-layered fabric region of a wovenfabric;

FIGS. 4B-4G are cross-sectioned views as in FIG. 4A, depicting at leastone embodiment of a series of steps to form two opposing layerscomprising a multi-layered fabric region of a woven fabric;

FIG. 5 is a plan view of a woven fabric adapted for forming componentsfor use in making a pair of shorts, according to at least oneembodiment;

FIG. 6 is a plan view of a woven fabric adapted for forming componentsfor use in making a pair of shoes, according to at least one embodiment;

FIG. 7 is a plan view of a woven fabric adapted for forming variouscomponents for use in forming a jacket, according to at least oneembodiment;

FIG. 8 is a plan view of a woven fabric adapted for forming variouscomponents for use in forming a jacket, according to at least one otherembodiment; and

FIG. 9 is a flow diagram illustrating a method for making an item ofapparel according to at least one implementation.

DETAILED DESCRIPTION

The illustrations presented herein are, in some instances, not actualviews of any particular woven fabric, apparel component or apparel item,but are merely idealized representations which are employed to describevarious aspects of the present disclosure. Additionally, elements commonbetween figures may retain the same numerical reference designation.

Various embodiments of the present disclosure relate to woven fabricsfor forming components suitable for use, for example, in items ofapparel. The woven fabric described herein may comprise a fabric that iswoven as a continuous web in such a way that, over selected regions ofthe fabric, the fabric is woven in two or more layers with the warps andwefts of each layer being distinct from the warps and wefts of the otherlayer, while in other regions the warps and wefts of the two or morelayers are woven together as a single layer. In at least someembodiments, the warps and wefts of the two or more layers can be woventogether as a single layer by introducing a pattern of woven stitches inwarp and/or weft directions. In one or more other embodiments, the warpsand wefts of the two or more layers can be woven together byinterweaving the warps of both the layers into a single layer with thesame group of wefts and by interweaving the wefts of both layers withthe same groups of warps. The fabric thus woven is produced as acontinuous web from which individual components of an item of apparelare subsequently formed by cutting the web along predetermined lines.

With reference to the accompanying drawings, FIG. 1 is a cross sectionview of a woven fabric 100 according to at least one embodiment. Forsimplicity of discussion, the woven fabric 100 will be discussed in thecontext of a particular weft pattern, although equally within the scopeof this disclosure is the same fabric 100 woven where weft yarns andwarp yarns are interchanged in their positions, thus producing a similarfabric 100. Therefore, specific reference to warp or weft yarns in thebelow discussion should not limit the scope of the woven fabric 100where warp yarns 110 are interchangeable with weft yarns 120.

One or more warp yarns 110 may be interwoven with one or more weft yarns120. As displayed, the one or more warp yarns 110 may include four setsof warp yarns 110, including first and second pairs 130, 135 of warpyarn sets. Although single warp yarn threads 110 are shown, each warpyarn thread 110 may represent a single warp yarn comprising a warp yarnset, or a plurality of warp yarns that comprise a warp yarn set. In theactual weaving process of the woven fabric 100, a warp yarn setcomprising a plurality of warp yarns may be implemented by positioningeach of the warp yarns in the warp yarn set in like manner to itscorresponding single warp yarn depicted. Similarly, although only singleweft yarns 120 are shown, each weft yarn thread 120 may represent asingle weft yarn comprising a weft yarn set, or a plurality of weftyarns that comprise a weft yarn set. Where the weft yarn set comprises aplurality of weft yarns, each of the weft yarns of the weft yarn set canbe positioned in like manner to its corresponding single weft yarndepicted. Consequently, the four warp yarns 110 displayed in FIG. 1 canrepresent four sets of warp yarns 110, where each set comprises one ormore warp yarns, and each weft yarn 120 can represent individual sets ofweft yarns 120, where each set comprises one or more weft yarns.

FIG. 2 shows an example where warp yarn sets 210 a, 210 b comprise aplurality of individual warp yarns, and where weft yarn sets 220 a, 220b comprise a plurality of individual weft yarns. As shown, the first setof weft yarns 210 a form a set of yarns extending at least substantiallyin parallel, passing over and under the same sets of warp yarns, and thesecond set of weft yarns 210 b also form a set of yarns extending atleast substantially in parallel, passing over and under the same sets ofwarp yarns. Similarly, the first and second sets of warp yarns 220 a,220 b form respective sets of yarns which extend at least substantiallyin parallel, passing over and under the same sets of weft yarns.

Referring again to FIG. 1, it should be noted that the number of yarnsin each set of weft yarns and/or warp yarns may vary across the fabric.For example, the weft yarn set 120 a may comprise one or more yarnswhile the weft yarn set 120 b comprises a different number of yarns.Furthermore, the number of yarns in a particular set of weft and/or warpyarns may vary at different regions in the fabric. For example, the weftyarn set 120 a may comprise one or more yarns in a first region, andthen the weft yarn set 120 a may comprise a different number of yarns inanother region. It is noted, therefore, that the actual number of yarnsin any of the various warp and/or weft sets can vary as desired for aparticular application.

Referring still to FIG. 1, in at least one embodiment, the first pair130 of warp yarn sets may include first and second sets 110 a, 110 b ofwarp yarns. The second pair 135 of warp yarn sets may include third andfourth sets 110 c, 110 d of warp yarns. The woven fabric 100 can bewoven by creating at least two general fabric regions, a multi-layeredfabric region 140, and a single-layered fabric region 150. When themulti-layered fabric region 140 is weaved, first and second pairs 130,135 of warp yarn sets may alternately correspond to, respectively, firstand third sets 110 a, 110 c of warp yarns, and second and fourth sets110 b, 110 d of warp yarns, as will be described hereafter.

The multi-layered fabric region 140 and the single-layered fabric region150 are weaved from the same sets of warp yarns 110 and weft yarns 120,forming an integral, woven fabric 100. The single-layered region 150 canbe weaved with first and second warp yarn sets 110 a, 110 b woven over afirst weft yarn set 120 a, while third and fourth warp yarn sets 110 c,110 d can be woven under the first weft yarn set 120 a. Further, thefirst and second warp yarn sets 110 a, 110 b can be woven under a secondweft yarn set 120 b, while third and fourth warp yarn sets 110 c, 110 dcan be woven under the second weft yarn set 120 b. This manner ofweaving produces a weaving pattern, which may be repeated to form adesired length of single-layered fabric region 150.

One skilled in the art will appreciate that other ways of alternatingweaving warp yarn sets (110 a, 110 b, 110 c, 110 d) may create thesingle-layered fabric region 150, such as by weaving one set of warpyarns over a first weft yarn set 120 a while weaving the other threesets of warp yarns (or the remainder of the four sets of warp yarns)under the first weft yarn set 120 a. Weaving warp yarn sets around asecond weft yarn set 120 b could follow the one/three split of warp yarnsets, or change back to weaving first and second pairs 130, 135 of warpyarn sets on either side of subsequent set of weft yarns 120.Furthermore, more than four warp yarn sets may be used. Consequently,there are multiple ways to weave the single-layered fabric region 150,which may result in an integral, single piece of woven fabric.

The multi-layered fabric region 140 may be weaved from the sameplurality of warp yarns 110 and weft yarns 120 as used to weave thesingle-layered fabric region 150. That is, the first warp yarn set 110 acan be woven over a third weft yarn set 120 c while third warp yarn set110 c is woven under the third weft yarn set 120 c. Further, first warpyarn set 110 a may be woven under a fourth weft yarn set 120 d whilethird warp yarn set 110 c is woven over the fourth weft yarn set 120 d.Additionally, second warp yarn set 110 b is woven over a fifth weft yarnset 120 e while the fourth warp yarn set 110 d is woven under the fifthweft yarn set 120 d. Further, second warp yarn set 110 b is woven undera sixth weft yarn set 120 f while fourth warp yarn set 110 d is wovenover the fifth weft yarn set 120 f. This manner of weaving produces aweaving pattern, which may be repeated to form a desired length ofmulti-layered fabric region 140.

In the embodiment depicted in FIG. 1, the first and third warp yarn sets110 a, 110 c are alternately woven around third and fourth weft yarnsets 120 c, 120 d to form a first woven fabric layer 160. Likewise, thesecond and fourth warp yarns sets 110 b, 110 d are alternately wovenaround fifth and sixth weft yarn sets 120 d, 120 f to form an opposing,second woven fabric layer 170. The weaving of first and second opposing,woven fabric layers 160, 170 may occur in parallel and concurrently forefficiency, i.e., during a weaving process. To make the multi-layeredfabric region 140 of desired length, the weaving of first and secondopposing, woven fabric layers 160, 170 is repeated until the desiredlength is obtained. After the multi-layered fabric region 140 is wovenin the weaving process, the weaving can transition to again form asingle-layered fabric region 150, as described previously.

FIG. 3 is a perspective view of one embodiment of weaving a fabric 100with a loom, such as a Jacquard Loom 300 having a plurality of liftingbars 310. As before mentioned, the warp yarns 110 may be interchangeablewith the weft yarns 120 in the woven fabric 100. Therefore, although thefollowing embodiment is described with particular configurations of warpyarns 110 about weft yarns 120, other embodiments of the weaving processcan include similar configurations of weft yarns 120 about warp yarns110.

Warp yarns sets 110 a, 110 b, 110 c, 110 d are spun from at least onewarp yarn spool 320, although multiple warp yarn spools 320 could beused, for instance, one each for warp yarn set pairs 130, 135. Warpyarns 110 are fed into lifting bars 310 of the Jacquard Loom 300. Aseach set of warp yarns 110 is lifted as directed by a computer or punchcard (not shown), a weft yarn spool 330 inserts (or picks) one or moreweft yarns 120 through the warp yarn sets 110. Weights (not shown) maybe used to batten, or press home, the weft yarns 120 into woven fabric100, which exits onto a fabric spool 340. The alternation of the warpyarns 110 and weft yarns 120 to produce the woven fabric 100 wasexplained briefly in reference to FIG. 1. Note that the woven fabric100, as shown, can comprise various alternating patterns ofmulti-layered fabric region 140 and single-layered fabric region 150,which may be used to produce items of apparel and/or components for usedin items of apparel.

FIGS. 4A-4G display a more detailed set of steps that may be used forweaving a woven fabric 100, according to at least one embodiment. Eachof FIGS. 4A-4G show a cross-section view of a portion of a Jacquard Loom300, depicting four sets (410 a, 410 b, 410 c, 410 d) of alternatingwarp yarns 410 woven around sets of weft yarns 420. FIG. 4A shows thefour warp yarn sets interwoven with a first weft yarn set 420 a formedin a single-layered fabric region 150. This may provide a starting pointbefore a multi-layered fabric region is woven. As depicted, the firstand second warp yarn sets 410 a, 410 b may be woven over the first weftyarn set 420 a and third and fourth warp yarn sets 410 c, 410 d may bewoven under the first weft yarn set 420 a. First, second, third, andfourth warp yarn sets 410 a, 410 b, 410 c, 410 d may be coupled tocorresponding first, second, third, and fourth sets 310 a, 310 b, 310 c,310 d of lifting bars 310 of Jacquard Loom 300.

FIG. 4B shows a first step to weaving a multi-layered fabric region 140according to one exemplary embodiment. After the third set 310 c oflifting bars is raised, the second weft yarn set 420 b is insertedthrough the gap created between first and third warp yarn sets 410 a,410 c. The arrows superimposed adjacent first and fourth sets 310 a, 310d of lifting bars indicate that these are to be raised in the next step.

FIG. 4C shows the result of raising first and fourth sets 310 a, 310 dof lifting bars, creating another gap, this time between second andfourth warp yarn sets 410 b, 410 d, through which is inserted the thirdweft yarn set 420 c. The arrows superimposed adjacent third and fourthsets 310 c, 310 d of lifting bars indicate that these are to be droppedin the next step.

FIG. 4D shows the result of dropping third and fourth sets 310 c, 310 dof lifting bars, creating another gap between first and third warp yarnssets 410 a, 410 c, through which is inserted the fourth weft yarn set420 d. The arrows superimposed adjacent second and third sets 310 b, 310c of lifting bars indicate that these are to be raised in the next step.

FIG. 4E shows the result of raising second and third sets 310 b, 310 cof lifting bars, creating another gap between second and fourth warpyarn sets 410 b, 410 d, through which is inserted a fifth weft yarn set420 e. The arrows superimposed adjacent first and second sets 310 a, 310b of lifting bars indicate that these are to be dropped in the nextstep.

FIG. 4F shows the result of dropping first and second sets 310 a, 310 bof lifting bars, creating another gap between first and third warp yarnsets 410 a, 410 c, through which is inserted a sixth weft yarn set 420f. The arrows superimposed adjacent first and fourth sets 310 a, 310 dof lifting pairs indicates these are next to be raised.

If the weaving process were to end at this point, FIG. 4G shows theresult of six sets of weft yarns 420 having been alternately woven intofour warp yarn sets 410 in a parallel weaving process. As displayed, afirst woven fabric layer 460 comprises first and third warp yarn sets410 a, 410 c. Also, second woven fabric layer 470 comprises second andfourth warp yarn sets 410 b, 410 d. The exact assigned number of therespective warp yarn sets of first and second woven fabric layers 460,470 are only exemplary for ease of explanation, and are not meant toprovide limitations to the scope of this disclosure. Nevertheless, itshould be apparent that first and second woven fabric layers 460, 470are separated and opposing in relation, thereby forming space therebetween. The weaving process may continue to form a multi-layered fabricregion 140 of desired length, and through the pattern controlled by thecomputer of a Jacquard Loom 300, may weave at least one, single-layeredfabric region 150.

It should be noted that use of one or more of the embodiments of theweaving process herein described enables the weaving of bothmulti-layered fabric regions 140 and single-layered fabric regions 150from the same sets of warp yarns (410 a, 410 b, 410 c, 410 d) during acontinuous weaving process. Note that each of the first and second wovenfabric layers 460, 470 may be of varying lengths, if desired, to producevarying dimensions to parts of an apparel component. This may still beaccomplished through the same, continuous weaving process by simplycontinuing to weave one of the first and second woven fabric layers 460,470 while stopping for a time the weaving of the other of the first andsecond woven fabric layers 460, 470.

Turning to FIGS. 5-8, various examples of woven fabric configurationsare illustrated, which are adapted for generating various components forarticles of clothing. FIG. 5 is a plan view of a woven fabric 500adapted for forming components for use in making a pair of shorts,according to at least one embodiment. As illustrated, the woven fabric500 is formed comprising at least one single-layered fabric region 502,and one or more multi-layered fabric regions 504 a, 504 b. Thesingle-layered fabric region 502 may be formed in a manner similar tothe single-layered fabric region described above. In the alternative,the single-layered fabric region 502 can comprise two or more layersthat are interconnected by woven stitching in warp and/or weftdirections. Additionally, the single-layered fabric region 502 can beformed using the same weaving pattern throughout the woven fabric 500,or the singe-layered fabric region 502 can be formed using differentweaving patterns in different locations in the woven fabric 500.

The multi-layered fabric regions 504 a, 504 b can be formed in a mannersimilar to the multi-layered fabric region described above, with two ormore separate layers. The multi-layered fabric region 504 a, 504 b mayprovide alternative weaving patterns and design effects in the wovenfabric 500, and/or may provide functional features associated with acomponent in the woven fabric 500. For example, the multi-layered fabricregion 504 a may be included to provide design elements and visualeffects to the woven fabric 500. In the example shown, the multi-layeredfabric region 504 a comprises two different weave patterns, 506 and 508.The first weave pattern 506 of the multi-layered fabric region 504 a cancomprise longer “floats” to make the fabric appear more shiny andsmooth. A “float” is where one set of yarns passes over or undermultiple transversely extending yarns or sets of yarns. For example, inthe first weave pattern 506, the weft yarn sets may extend over andunder two or more warp yarn sets to provide the longer floats described.The second weave pattern 508 may comprise shorter “floats” and/orvarying patterns to provide other textures to the multi-layered fabricregion 504 a.

In addition to providing design effects to the woven fabric 500, amulti-layered fabric region 504 a, 504 b may also provide functionalfeatures to the woven fabric 500. For example, the multi-layered fabricregion 504 b can comprise two layers forming an elongated opening orpocket. This pocket between the two layers can be positioned through aportion comprising the waistband of the shorts and can be configured toreceive a drawstring there through. In this manner, no additional sewingwill be required to form such a drawstring pocket, as it is integrallyformed in the woven fabric 500.

When the woven fabric 500 is completed, the two components for theshorts can be cut out along the broken lines 510. As shown, thecomponents can be cut through a portion of the multi-layered fabricregion 504 b to provide access to the elongated opening through which adrawstring can be disposed. These components can subsequently be coupledtogether by, for example, sewing the components together to form thedesired shorts. It should be apparent that similar features may also beemployed in a pair of pants by simply extending out leg portions of thecomponents.

FIG. 6 is a plan view of a woven fabric adapted for forming componentsfor use in making a pair of shoes, according to at least one embodiment.The woven fabric 600 shown in FIG. 6 is adapted to form three componentsof a shoe, a main upper component 602, a heel component 604 and a tonguecomponent 606. Two sets of components are shown for forming a matchingpair of shoes—for left and right feet.

The various components can be formed from a combination ofsingle-layered fabric regions 608 and multi-layered fabric regions 610.In some embodiments, the different fabric regions 608, 610 can beimplemented for providing a variety of ornamentation and/or visualeffects in a single woven fabric component, as opposed to conventionalshoe assemblies using individual components of differently configuredfabrics that must be sewn together.

The single-layered fabric region 608 may be formed in a manner similarto the single-layered fabric region described above with reference toFIGS. 1-4. In the alternative, the single-layered fabric region 608 cancomprise two or more layers that are interconnected by woven stitchingin warp and/or weft directions. Additionally, the single-layered fabricregion 608 can be formed using the same weaving pattern throughout thewoven fabric 600, or the singe-layered fabric region 608 can be formedusing different weaving patterns in different locations in the wovenfabric 600.

The multi-layered fabric regions 610 can be formed in a manner similarto the multi-layered fabric region described above with reference toFIGS. 1-4, with two or more separate layers. The multi-layered fabricregions 610 may provide alternative weaving patterns and/or designeffects in the woven fabric 600. For example, the multi-layered fabricregions 610 can comprise a plurality of different weave patterns, suchas weave patterns 612 and 614. The first weave pattern 612 of themulti-layered fabric region may comprise longer “floats” to make thefabric appear more shiny and smooth, and the second weave pattern 614may comprise shorter “floats” and/or varying patterns to provide othertextures to the multi-layered fabric region 610.

When the woven fabric 600 is completed, the various components for theshoes can be cut out along the broken lines illustrated for eachcomponent. These components can subsequently be coupled together by, forexample, sewing the components together to form the desired upperportion of a shoe, and the completed upper portion can subsequently becoupled to a sole to complete the shoes.

FIG. 7 is a plan view of a woven fabric adapted for forming variouscomponents for use in forming a jacket, according to at least oneembodiment. The woven fabric 700 is formed with various single-layeredfabric regions 702 and multi-layered fabric regions 704 a-704 dconfigured in a manner to obtain various jacket components including abody component 706, two hood components 708 and four sleeve components710.

The single-layered fabric region 702 may be formed in a manner similarto the single-layered fabric region described above with reference toFIGS. 1-4. In the alternative, the single-layered fabric region 702 cancomprise two or more layers that are interconnected by woven stitchingin warp and/or weft directions. Additionally, the single-layered fabricregion 702 can be formed using the same weaving pattern throughout thewoven fabric 700, or the singe-layered fabric region 702 can be formedusing different weaving patterns in different locations in the wovenfabric 700.

The multi-layered fabric regions 704 a-704 d can be formed in a mannersimilar to the multi-layered fabric region described above withreference to FIGS. 1-4, with two or more separate layers. Themulti-layered fabric regions 704 a-704 d may provide alternative weavingpatterns and/or design effects in the woven fabric 700, and at leastsome of the multi-layered fabric regions 704 a-704 d can be configuredto provide functional features to the woven fabric 700. For example, themulti-layered fabric region 704 a can comprise two layers adapted toform an elongated opening for receiving a drawstring in hood components708. Similarly, the multi-layered fabric regions 704 b and 704 c canalso be adapted to form elongated openings for receiving drawstrings inthe body component 706 that may be used for tightening the jacket aroundthe a user. The multi-layered fabric regions 704 d are examples offeatures in the woven fabric 700 adapted to be implemented as pockets.

When the woven fabric 700 is completed, the various components for thejacket can be cut out along the broken lines illustrated for eachcomponent. These components can subsequently be coupled together by, forexample, sewing the components together to form the desired jacket. Itis noted that similar components may be modified for making a shirt,sweatshirt, coat, etc.

FIG. 8 is a plan view of a woven fabric adapted for forming variouscomponents for use in forming another jacket, according to at least oneembodiment. The woven fabric 800 is formed with various single-layeredfabric regions 802 and multi-layered fabric regions 804 configured in amanner to obtain various jacket components. The single-layered fabricregion 802 may be formed in a manner similar to the single-layeredfabric region described above with reference to FIGS. 1-4. In thealternative, the single-layered fabric region 802 can comprise two ormore layers that are interconnected by woven stitching in warp and/orweft directions. The single-layered fabric region 802 can be formedusing the same weaving pattern throughout the woven fabric 800, or thesinge-layered fabric region 802 can be formed using different weavingpatterns in different locations in the woven fabric 800.

The multi-layered fabric regions 804 can be formed in a manner similarto the multi-layered fabric region described above with reference toFIGS. 1-4, with two or more separate layers. The multi-layered fabricregions 804 may provide alternative weaving patterns and/or designeffects in the woven fabric 800 for providing design elements and visualeffects, and at least some of the multi-layered fabric regions 804 canbe configured to provide functional features to the woven fabric 800.For example, the multi-layered fabric region 804 a can comprise twolayers adapted to form an elongated opening for receiving a drawstringin hood components for the jacket. The multi-layered fabric regions 804b are examples of features in the woven fabric 800 adapted to beimplemented as pockets.

When the woven fabric 800 is completed, the various components for thejacket can be cut out along the broken lines illustrated for eachcomponent. These components can subsequently be coupled together by, forexample, sewing the components together to form the desired jacket. Itis noted that similar components may be modified for making a shirt,sweatshirt, coat, etc.

Although only a few examples of items of apparel have been shown oridentified to provide a general description of various features of thepresent disclosure, it should be apparent to a person skilled in the artthat other items of apparel, as well as variations to the itemsdescribed can also be formed using fabric formed according to thetechniques described herein.

Additional embodiments of the present disclosure relate to methods ofmaking items of apparel which include fabric woven with a single-layeredregion and a multi-layered region. FIG. 9 is a flow diagram illustratingat least one implementation of a method 900 for making an item ofapparel including such fabric, according to at least one implementation.For example, referring to FIGS. 1 and 9, a woven fabric 100 may beformed at step 902. The woven fabric includes at least one multi-layeredregion 140 and at least one single-layered region 150. Forming the wovenfabric 100 to include both a multi-layered region 140 and asingle-layered region 150 may include weaving the multi-layered region140 and the single-layered region 150 from the same sets of warp yarnsand weft yarns to form an integral woven fabric.

The multi-layered region 140 comprises a first woven fabric layer 160and a second woven fabric layer 170 that is opposite from the firstwoven fabric layer 160, such that the first and second woven fabriclayers are separate and distinct from each other. For instance, warpsand wefts of the first woven fabric layer 160 are woven separate anddistinct from the warps and wefts of the second woven fabric layer 170.According to at least one implementation, the multi-layered region 140can be formed in a manner similar to the multi-layered fabric region 140described with reference to FIGS. 4A-4G herein above. Furthermore,according to various implementations, the multi-layered region maycomprise the same weave pattern throughout the woven fabric, or themulti-layered region may comprise two or more different weave patterns(e.g., differing float, etc.). In some implementations, the first wovenfabric layer 160 may be formed to comprise a length that is differentthan a length of the second woven fabric layer 170.

The single-layered region 150 may be formed in a manner similar to thesingle-layered fabric region 150 described above with reference to FIGS.4A-4G. For instance, the single-layered region 150 can be formed byweaving warps of both the first and second woven fabric layers with thesame sets of wefts, and by weaving wefts of both the first and secondwoven fabric layers with the same sets of warps. In otherimplementations, the single-layered fabric region 150 can comprise thefirst and second woven fabric layers interconnected by woven stitchingin warp and/or weft directions. According to various implementations,the single-layered region can comprise the same weave pattern throughoutthe woven fabric, or the single layered region can comprise two or moredifferent weave patterns (e.g., different float, etc.).

At step 904, the woven fabric 100 can be cut along a predeterminedpattern to form one or more components therefrom. According to at leastsome implementations, the components can be cut using conventionalfabric cutting means, including scissors, lasers, rotary cutters,knifes, razor blades, etc. With the one or more components cut from thewoven fabric 100, the one or more components may be coupled togetherand/or coupled with other components to form at least a portion of anitem of apparel at step 906. By way of example and not limitation, theone or more components can be coupled together and/or with othercomponents to form at least a portion of shorts, pants, shoes, jackets,shirts, sweatshirts, coats, or any other item of apparel.

The various embodiments and implementations of the present disclosureresult in fabric components and articles of apparel comprising wovenfabric that includes both a single-layered fabric region and amulti-layered fabric region formed integrally as a continuous web. Suchfeatures can provide increased strength to apparel features such aspockets and openings, and can reduce the total number of steps inproduction among other benefits.

Implementations and features of the present disclosure may be embodiedin other specific forms without departing from its structures, methods,or other essential characteristics as broadly described herein andclaimed hereinafter. The described embodiments are to be considered inall respects only as illustrative, and not restrictive. The scope of theinvention is, therefore, indicated by the appended claims, rather thanby the foregoing description. All changes that come within the meaningand range of equivalency of the claims are to be embraced within theirscope.

What is claimed is:
 1. A component adapted for use in an article ofclothing, the component including a woven fabric comprising: at leastone multi-layered region comprising a first woven fabric layer and asecond woven fabric layer that is opposite from the first woven fabriclayer, wherein the first and second woven fabric layers are separatedfrom each other; and at least one single-layered region; wherein thewoven fabric changes between the at least one multi-layered region andthe at least one single-layered region with the same sets of warps andwefts.
 2. The component of claim 1, wherein warps and wefts of the firstwoven fabric layer of the at least one multi-layered region are distinctfrom warps and wefts of the second woven fabric layer of the at leastone multi-layered region.
 3. The component of claim 1, wherein the atleast one single-layered region comprises warps and wefts of the firstand second woven fabric layers woven together as a single, woven fabriclayer.
 4. The component of claim 1, wherein the at least onemulti-layered region is configured as an opening in the woven fabric forcreating a pocket.
 5. The component of claim 1, wherein the at least onemulti-layered region is configured as an opening in the woven fabric forreceiving a drawstring.
 6. The component of claim 1, wherein each set ofwarps comprises one or more yarns, and each set of wefts comprises oneor more yarns.
 7. An article of clothing, comprising: a plurality ofcomponents coupled together, wherein at least one component of theplurality of components includes a woven fabric comprising: amulti-layered region comprising a first woven fabric layer and a secondwoven fabric layer, wherein warps and wefts of the first woven fabriclayer are distinct from warps and wefts of the second woven fabriclayer; and a single-layered region woven from the same groups of warpsand wefts used in the first and second woven fabric layers of themulti-layered region.
 8. The article of clothing of claim 7, wherein thesingle-layered region comprises: the warps of both the first and secondwoven fabric layers interwoven into a single layer with the same groupof wefts; and the wefts of both the first and second fabric layersinterwoven into a single layer with the same groups of warps.
 9. Thearticle of clothing of claim 7, wherein the plurality of components arecoupled together to form at least a portion of one of shorts, pants,shoes, a jacket, a shirt, a sweatshirt or a coat.
 10. The article ofclothing of claim 7, wherein the at least one multi-layered region isconfigured as an opening in the woven fabric for creating a pocket. 11.The article of clothing of claim 7, wherein the at least onemulti-layered region is configured as an opening in the woven fabric forreceiving a drawstring.
 12. The article of clothing of claim 7, whereineach warp comprises one or more yarns, and each weft comprises one ormore yarns.
 13. A method of making an item of apparel, the methodcomprising: forming a woven fabric including: at least one multi-layeredregion comprising a first woven fabric layer and a second woven fabriclayer that is opposite from the first woven fabric layer, wherein thefirst and second woven fabric layers are separated from each other; andat least one single-layered region; wherein the at least onemulti-layered region and the at least one single-layered region areweaved from the same sets of warps and wefts; and cutting the wovenfabric along a predetermined pattern to form one or more components fromthe woven fabric.
 14. The method of claim 13, wherein forming the wovenfabric including at least one multi-layered region comprises: weavingwarps and wefts of the first woven fabric layer; and weaving warps andwefts of the second woven fabric layer, wherein the warps and wefts ofthe first woven fabric layer are woven separate and distinct from thewarps and wefts of the second woven fabric layer.
 15. The method ofclaim 13, wherein forming the woven fabric including the at least onemulti-layered region comprises: forming the first woven fabric layerwith a length that is different than a length of the second woven fabriclayer.
 16. The method of claim 13, wherein forming the woven fabricincluding at least one single-layered region comprises: weaving warps ofboth the first and second woven fabric layers with the same sets ofwefts; and weaving wefts of both the first and second woven fabriclayers with the same sets of warps.
 17. The method of claim 13, whereineach set of warps comprises one or more yarns, and each set of weftscomprises one or more yarns.
 18. The method of claim 13, furthercomprising coupling the one or more components together.
 19. The methodof claim 13, wherein the at least one multi-layered region is configuredas an opening in the woven fabric for creating a pocket.
 20. The methodof claim 13, wherein the at least one multi-layered region is configuredas an opening in the woven fabric for receiving a drawstring.